Method of making insulating blocks in the field



May Z, i931. H. s. ASHENHURST LSSGQ METHOD 0F MAKING INSULATING BLOCKS IN THE FIELD 1 Filed Sept ina Orig

Patented May 12, 1931 UNITED` STATES PATENT OFFICE HAROLD S. ASHEN'HURST, OF CHICAGO, ILLINOIS, ASSIGNIOR, B'YLMES\NE ASSIGNMENTS. T INSULEXCORCPORATION, OF CHICAGO, ILLINOIS, A CORPORATION. 0F DELAWARE METHOD OF MAKING IN SUL-ATING BLOCKS THE FIELD Original application led September 10, 192A, Serial .'No. 736,893. Dividedand thil application #Jed March s; 1925. serial N0.'12,ss2.

This application is a division of my copendin application, Serial No.v 736,893, iiled Se tem r1() 1924;

t is the object of my present invention 5 to provide an improved method of making insulating blocks readyito be applied to a wall structure near at handuthereby avoiding the expense and trouble of shipping the blocks, avoiding the danger of breakage in la transit, avoiding the necessity of providing stood by lath secured space and time for the drying of the blocks after they are formed and before they are used, and affording the possibility of pro` viding a better fit and more ready applica.-

tion of the block. tightl in. osition where it is to serve. It is anot er o ject of my invention to provide that the resulting blocks and wall may be of high insulating and lireproofing value. s

The invention will be more readily underrefe-rence to the accompanying drawings, in which;

Fig. 1 is a perspective View of a temporary form with a quantity of the block-forming material thereln;

Fig. 2 is a transverse sectional A view through a vertical wall to which the insulat ing blocks have been applied against an outer .sheet er wall;

Fi 3 is a similar view showing a construction 1n which the blocks are applied against d to the studding on the inside, an s Y Fig. 4 is a view showing a method of con'- struction in which plaster is directly applied to the blocks toprovide a wall surface.

According to the method here disclosed, l provide at a point adjacent to the wall to be insulated, a o lane horizontal surface,"such as a Hoer 9, an place thereon side members 10, 11, 12 and 13, thereby defining a shallow rectangular, open-top space, the depth of the side members being preferably equal to the thickness of the blocks to be formed.v l then place inthe bottom of the space a facing member for the block in the form of a strip of building paper 14, and pour thereon a plastic mass composed of gypsum as the major ingredient, and chemicals that in thev presence of water will evolve a gas and cause theexpansion of the mass under such conditions that the mass is `adapted to set and harden in expanded cellular condition, as described and claimed in my prior reissue Patent No. 15,952,036 November 25, 1924. I wish it distinctl understood, however, that I contemplate tlile employment of any material b means of which a quick-setting cellular bloc of li ht weight may be formed.

en the material has risen and before setting is com lete, l prefer to level olf the top surface, eit er by screeding or trowelling. By this means ll not only provide a level top surface but also strengthen the surface by breaking down the cellular formation.

Shortl after the initial setting takes place, w ich occurs within 15 or 20 min-v v'utes after pouring, vand while'the materialis still relatively `soft and wet,'I subdivide the large block alon the lines 15,-into a plurality of smaller locks 15a, of the desired size and sha e. This is easily accomplished by employing a straighted e and a thin blade that will pass through t e cellular material and the paper at the bottom thereof. Thereafter l remove one? or more of the side members, preferably the member. 13, and lift the adjacent blockl from yits position.. The paper 14, adheres strongly to the block and serves as a reinforcement or base for the block.. lit will be understood that at this time the block is relatively soft, and without will rigidity to resist any substantial shocks or strains.

Immediately thereafter, if desired, the blocks ma ,be placed in a wall and in the drawings have illustrated a pllurality of studs 16, the space between' whic will preferabl correspond to the width of the blocks. The locks are removed from the yadjacent mold and-placed in superposecl relation to com lete the wall to the desired height.

In Fig. 2 I haveillustrated a wall having an outer' sheathing 18, suitably secured to the studding and the insulating blocks are placed against this wall with the paper backmg on the exposed side. Of course, if desired, blocks may be formed of such thickness a 'to' completely ill the space between the( studding, but for ordinar purposes this will be found unnecessary. f it be desired toprovidea wall to which plaster may -be applied, the blocks, indicated at 15b in Fig. '4, are so placed that a surface' other than the surface covered by the paper is placed flush with the surface of the studdin If strips of metal lath 19a are tacked to t e studding,

plaster 20 vmay readily be applied to the entire surface.- y

y In -3 a construction is shown in which the outer sheathing or coyering has not been applied. However, metal lath, indicated at 19, has been applied to the inner surface or the studdingv and theblocks 15a are placed thereagainst. It will be understood that the open side of the wall will be completed in an desired manner. i f l ile I have shown a wall having studs between which the blocks are received, it will be understood that I contemplate the insulation of a wall in the described manner. regardless of the vstructural characteristics of the wall. It is practical in some instances Yto build the wall without studding, merely placing the blocks in proper relation, one upon another. It is also possible to construct a wall havin relatively narrow studding and to complete y imbed the studding in the blocks by shaping the blocks around the stud ding in the `process of building; Such con struction is not, however, claimed in the present application. It will be understood that while I have illustrated a method' by which the blocks are formed by subdividin a larger block that is vcast in the eld, a e# l sirable result mightbe secured by separatei tice of my improve l castin the several blocks in the eld in t edescri d manner.

I have had very (goed results in the pracmethod by the use of a mixture of the following ingredients -100 marcial retarder, 3?/

pounds of calcined gypsum, 2 ounces o wmounds of a suitable carbonate such as c clum carbonate, and 8 pounds of aluminum sulphate containing its water of crystallization, all'of. such in e' nely ground and thor-ong y-l `mixed in a ry state.

Vclients bein I do not wish toclaimvby this a plication the subject-matter 'disclosed and caimed by copendinsg ap licatione,l Serial No'. 736,892,1i1ed I claim:

A1. The process of making Aa. light weight insulating block and reenforcing it and 1nserting it in a wall structure while istill green, which comprises casting the body of eptem r 1 0, 1924, and Serial d No. 12,883, filed March 3,1925.

Leonesa the block in a mold from plastic material ada ted to expand by chemical action and set in cellular condition in bonded relationship to a base member of fibrous material held stationary in said mold, said body material being exposed at the edges and one face .of the block, and shaping said block while still lastic into intimate engagement with the ad] acent elements of a wall.

2. The process of making a light weight insulating block and reenforcing it and inserting it in a wall structurewhile still tions of the block While sti llpastic into intimate en agement with the adjacent elements` of a wa l.

Signed at Chicago, 'llllinois, this 21th day or February, Ai'. D. 1925. HABLD ASHENHURST.

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